Adjustable last for manufacturing footwear and a method of manufacturing footwear using the adjustable last

ABSTRACT

A last for manufacturing footwear and a method for manufacturing footwear with the last, where the last includes a last body, at least one insert, and at least one fastener. The last body has an outer surface corresponding to an inner surface of an article of footwear to be manufactured. The last body includes at least one aperture. The at least one insert is configured to be inserted into the at least one aperture. The at least one faster is configured to removably fasten the at least one insert into the at least one aperture.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application No. 61/408,055, filed Oct. 29, 2010, which is incorporated herein by reference in its entirety.

BACKGROUND OF THE INVENTION

1. Field Of The Invention

This application relates to an adjustable last used for manufacturing footwear and a method for making different designs of footwear using the adjustable last.

2. Description Of The Related Art

Conventional lasts used for manufacturing footwear are a single integral piece of metal or plastic around which an article of footwear is constructed. Typically, a plastic last is used for manufacturing a piece of footwear that is constructed using adhesives, and a metal last is used for footwear that will undergo an autoclaving process during manufacture.

A conventional last is needed for each design, each size, and each width. As each last costs on the order of $80-100 or more, a set of lasts for a particular design is a substantial expense. Further, a custom footwear design that requires a new set of lasts will need to incorporate the costs of the entire set of lasts into the cost of the custom footwear. Accordingly, ordering a custom footwear design costs substantially more than purchasing footwear already mass-produced.

SUMMARY OF THE INVENTION

A last for manufacturing footwear and a method for manufacturing footwear with the last, where the last includes a last body, at least one insert, and at least one fastener. The last body has an outer surface corresponding to an inner surface of an article of footwear to be manufactured. The last body includes at least one aperture. The at least one insert is configured to be inserted into the at least one aperture. The at least one faster is configured to removably fasten the at least one insert into the at least one aperture.

The method of manufacturing an article of footwear of a first design and an article of footwear of a second design may include: fastening at least one insert into at least one aperture of a last body using at least one fastener; manufacturing the article of footwear of the first design around the last body; removing the article of footwear from the last body; removing the at least one insert from the at least one aperture of the last body; forming the article of footwear of the second design around the last, the article of footwear of the second design having a component located in the at least one aperture; and manufacturing the article of footwear of the second design around the last body.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:

FIG. 1 is a top view of a last according to an exemplary embodiment of the present invention;

FIG. 2 is a side view of a last according to an exemplary embodiment of the present invention;

FIG. 3 is a rear perspective view of a last according to an exemplary embodiment of the present invention;

FIG. 4 is a perspective side view of a last according to an exemplary embodiment of the present invention;

FIG. 5 is a rear perspective view of a last according to an exemplary embodiment of the present invention; and

FIG. 6 is a top view of a piece of footwear made with a last according to an exemplary embodiment of the present invention;

FIG. 7 is a side view of a last according to exemplary embodiment of the present invention with a piece of footwear constructed around it;

FIG. 8 is a top view of a piece of footwear made with a last according to an exemplary embodiment of the present invention;

FIG. 9 is a flowchart showing an exemplary method for using the lasts according to the present invention;

FIG. 10 is a side perspective view of a first insert according to an alternative embodiment of the fastener of the present invention; and

FIG. 11 is a side perspective view of a second insert according to the alternative embodiment of the fastener of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views.

FIG. 1 shows a top view of an exemplary embodiment of the present invention. In this exemplary embodiment, last 200 includes apertures 201 size to receive inserts 202. Thus, an surface of insert 202 that faces aperture 201 matches the surface of aperture 201 such that insert 202 can be firmly secured in aperture 201 without moving, as shown in FIGS. 1, 3, and 4.

Inserts 202 are removably fixed within apertures 201 by fasteners 203, as shown in FIG. 2. Fasteners 203 can be screws, rivets, or any other removable faster known in the art. An alternative structure for fastening insert 202 into last 200 is shown in FIGS. 10 and 11. Fasteners 203 are received by fasteners holes 204, shown in FIGS. 3 and 4.

Apertures 201 in the exemplary embodiment are located in an ankle area of the footwear. However, apertures can be located anywhere on the last 200. Further, any number of apertures can be included in last 200, depending on the designs of footwear to be manufactured with last 200.

The inserts 202 and apertures 201 allow last 200 to be used to manufacture at least two different designs of footwear. When inserts 202 are removably fixed in apertures 201, last 200 has a smooth surface in the ankle area, as shown for example in FIG. 5. In this configuration, last 200 and be used to manufacture a piece of footwear 300 that has a smooth internal surface 310 in the ankle area, as shown in FIG. 6.

When inserts 202 are removed from apertures 201, apertures 201 in the ankle area are exposed. Accordingly, in this configuration, last 200 is used to manufacture a piece of footwear 400 that has some kind of insert or additional component 410 that fits into aperture 201. A top view of such a piece of footwear 400 including additional component 410 is shown in FIG. 8.

FIG. 7 shows last 200 being used to manufacture footwear 400 of the second style. In the configuration shown in FIG. 7, inserts 202 are removed from apertures 201. Accordingly, the second piece of footwear as shown in FIG. 8 with additional components 410 that fit into apertures 201 can be manufactured. In one embodiment, additional components 410 include memory foam.

Additional components 410 may be included to provide a closer fit to the foot, especially when manufacturing boots. This is due to the fact that boots need to provide extra room to allow a foot to slide in easily, but require a closer fit when walking to avoid discomfort. Accordingly, additional components 410 can be included in such a boot to provide such a closer fit. However, if additional component 410 is included during manufacture using a last without an aperture such as aperture 201, additional component 410 may cause a bulge in the outer surface of the final piece of footwear. Accordingly, apertures 201 are needed in the last to receive any additional components that are needed to provide a close fit. As noted previously, the present invention includes lasts having apertures 201 anywhere on the last to receive any components necessary to provide an appropriate fit for the footwear being manufactured.

In this regard, the footwear shown in both FIGS. 6 and 8 can be made with the same last 200. Accordingly, the substantial costs of lasts 200 for each size and width can be shared by two or more designs of footwear. Further, as noted above, other inserts and apertures can be included in last 200, allowing one set of lasts to be used to make many different designs of footwear. Again, the cost of the lasts us can then be shared by all these different designs. Finally, multiple designs of custom footwear can share lasts, allowing sharing costs across the multiple custom footwear designs, reducing the price of custom footwear. Accordingly, custom ordered footwear can be more price competitive with mass-produced footwear.

In one embodiment, when generating a set of lasts for an entire range of sizes and widths, the aperture and insert sizes can remain the same across 3-4 shoe sizes. In another embodiment, the aperture and insert sizes can be unique for each shoe size.

Last 200 can be made of plastic or metal, as previously noted. If last 200 is made of metal, a vulcanization process can be used when manufacturing the footwear. In this case, inserts 202 and fasteners 204 may be made of metal as well.

An exemplary method using these lasts is shown in FIG. 9. In step S1, inserts 202 are fixed into apertures 201 of last 200. In step S2, footwear 300 of a first style is manufactured. In step S3, inserts 202 are removed from apertures 201 of last 200. Finally, in step S4, footwear 400 of a second style is manufactured. As noted previously, a plurality of apertures for receiving a plurality of corresponding inserts can be included in the lasts, allowing for a plurality of different designs to be manufactured with the same last. Methods that manufacture different designs of footwear in any order by including or removing the inserts from the corresponding apertures are included in the present invention.

FIGS. 10 and 11 illustrate an alternative structure for fastening insert 202 into last 200. FIG. 10 shows a last 200 including an aperture 206 for receiving dovetail fastener 205 of insert 202. Insert 202 fills in aperture 201 when fastener 205 is inserted into aperture 206.

When it is desired to make footwear in which aperture 201 is not filled in, dovetail fastener 305 is inserted in aperture 206, as shown in FIG. 11. Dovetail fastener 305 has a curved outer surface to match the surface of aperture 201.

Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein. 

1. A last for manufacturing footwear comprising: a last body having an outer surface corresponding to an inner surface of an article of footwear to be manufactured, the last body including at least one aperture; at least one insert configured to be inserted into the at least one aperture; and at least one faster configured to removably fasten the at least one insert into the at least one aperture.
 2. The last according to claim 1, wherein a surface of the least one aperture matches a corresponding surface of the least one insert that is received by the at least one aperture.
 3. The last according to claim 1, wherein the at least one fastener is a screw.
 4. The last according to claim 1, wherein the last body is made of metal.
 5. A method of manufacturing an article of footwear using the last according to claim 1, comprising: fastening the at least one insert into the at least one aperture using the at least one fastener; forming the article of footwear around the last body; and vulcanizing the article of footwear.
 6. The method of manufacturing according to claim 5, further comprising: removing the article of footwear from the last body; removing the at least one insert from the at least one aperture; and forming an article of footwear of a second design around the last, the article of footwear of the second design having a component located in the at least one aperture.
 7. A method of manufacturing an article of footwear of a first design and an article of footwear of a second design, comprising: fastening at least one insert into at least one aperture of a last body using at least one fastener; manufacturing the article of footwear of the first design around the last body; removing the article of footwear from the last body; removing the at least one insert from the at least one aperture of the last body; forming the article of footwear of the second design around the last, the article of footwear of the second design having a component located in the at least one aperture; and manufacturing the article of footwear of the second design around the last body.
 8. The method according to claim 7, wherein a surface of the least one aperture matches a corresponding surface of the least one insert that is received by the at least one aperture.
 9. The method according to claim 7, wherein the at least one fastener is a screw.
 10. The method according to claim 7, wherein the last body is made of metal.
 11. The method according to claim 7, wherein the component is made of memory foam.
 12. The method according to claim 7, further comprising: vulcanizing the article of footwear of the first design before removing the article of footwear from the last body; and vulcanizing the article of footwear of the second design after manufacturing the article of footwear of the second design around the last body. 